Non-combustible high pressure laminate

ABSTRACT

A high pressure laminate includes a first layer of resin impregnated paper and at least one layer of fiber reinforced veil. Each layer of fiber reinforced veil includes binder and filler. The laminate is characterized by having a caloric value of lower than  3.0  MJ/kg when tested in accordance with ISO  1716.  A method for producing this high pressure laminate is also provided.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

This invention relates generally to high pressure laminates and moreparticularly to a high pressure laminate complying with prEN 13823 andhaving a caloric value of lower than 3.0 MJ/kg when tested in accordancewith ISO 1716.

BACKGROUND OF THE INVENTION

High pressure laminates (HPL) are well known in the art and HPL panelsare used, for example, as wall linings, for furniture, facade cladding,bench tops and the like.

One of the most important parameters of HPL panels, especially in thebuilding industry, is fire performance. Since 2003, all buildingmaterials in Europe must comply with prEN 13823 (reaction to fire testsfor building products). This norm describes the Single Burning Item(SBI) test. A1 and A2 classification of additional caloric valuemeasurement according to ISO 1716 is required.

State of the art HPL panels are made fire retardant by using fireretardant kraft paper or by using a fire retardant phenol-formaldehyderesin. State of the art FR-HPL products have achieved an SBIclassification of as high as B (above 3.0 MJ/kg when tested under ISO1716).

HPL manufacturers have a strong desire for an SBI A2 classified HPLpanel. Such a classification would allow the manufacturers to expand theapplication range for their products and thereby penetrate additionalmarkets. To date, this hasn't been achieved because no one has been ableto meet the caloric value requirement and still achieve the desiredmechanical properties and fire propagation characteristics. The presentinvention relates to the first HPL panel meeting all these requirementsincluding those for A2 classification (below 3.0 MJ/kg when tested underISO 1716).

SUMMARY OF THE INVENTION

The high pressure laminate of the present invention comprises a firstlayer of resin impregnated paper and at least one layer of fiberreinforced veil. Each layer of fiber reinforced veil includes both asecondary binder and a filler. The high pressure laminate ischaracterized by having a caloric value of lower than about 3.0 MJ/kgwhen tested in accordance with ISO 1716.

The laminate may further include a second layer of resin impregnatedpaper. In such an embodiment the layer or layers of fiber reinforcedveil are sandwiched between the first and second layers of resinimpregnated paper.

In any of the possible embodiments the secondary binder is a heatcurable resin. Typically the binder is selected from a group consistingof melamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxyresin, unsaturated polyesters, cross-linkable acrylic resin,polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, anepichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin andmixtures thereof. The filler is typically selected from a groupconsisting of metal hydroxides, metal carbonates, titanium dioxide,calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zincoxide, kaolin clay, chlorite, diatomite, feldspar, mica, nephelinesyenite, pyrophyllite (aluminum silicate), silica, talc, wollastonite,montmorillonite (bentonite), hectorite, saponite, calcium carbonate,magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide,glass micro beads and mixtures thereof.

In a particularly preferred embodiment the filler is selected from agroup consisting of metal hydroxides, metal carbonates and mixturesthereof. A mixture of calcium carbonate and aluminum hydroxide is aparticularly useful filler for the present invention. This isparticularly true when the binder is melamine-formaldehyde.

In one possible embodiment each layer of fiber reinforced veil includesbetween about 1 and about 95 weight percent reinforcement fibers about 5and about 50 weight percent melamine-formaldehyde, between about 10 andabout 80 weight percent calcium carbonate and about 20 and about 90weight percent aluminum hydroxide.

Still further describing the invention, each fiber reinforced veilincludes reinforcing fibers that may be selected from a group consistingof glass fibers, basalt fibers, inorganic fibers and mixtures thereof.Typically the fibers are chopped. In a particularly useful embodimentthe veil includes chopped glass fibers. The chopped fibers may includestrands, rovings and individual chopped glass fibers or mixturesthereof. The glass fibers may, for example, be made from E-glass,ECR-glass, AR-glass, C-glass, M-glass, S-glass, S2-glass and mixturesthereof

The fiber reinforced veil may be woven or nonwoven. Where multiplelayers of fiber reinforced veil are provided, they may all be woven,they may all be nonwoven or the layers may be a mixture of woven andnonwoven.

The high pressure laminate of the present invention may be made moreaesthetically appealing when the first layer of resin impregnated paperis a melamine impregnated decor paper. Further, the product may includea radiation cured paint film or coating such as a UV cured paint film oran electron beam cured paint film on an exposed face of the first layerof resin impregnated paper. In yet another alternative the product mayinclude a thermally cross-linked urethane acrylate paint layer on anexposed face of the first layer of the resin impregnated paper.

In accordance with yet another aspect of the present invention a methodis provided for making a high pressure laminate. That method comprisespressing a first layer of resin impregnated paper and at least one layerof fiber reinforced veil together at a pressure of between about 525N/m² and about 15,750 N/m² while simultaneously heating the layers to atemperature of between about 120 degrees C. and about 220 degrees C. toform a laminate. In addition the method includes the step of using acombination of secondary binder and filler to provide a caloric value oflower than 3.0 MJ/kg when the laminate is tested in accordance with ISO1716.

The method may further include the selecting of the secondary binderfrom a group consisting of melamine-formaldehyde, phenol-formaldehyde,urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkableacrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamideresin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamideresin and mixtures thereof. The filler may be selected from a groupconsisting of metal hydroxides, metal carbonates and mixtures thereof.In a particularly useful embodiment the filler is selected from amixture of calcium carbonate and aluminum hydroxide.

In one possible embodiment the method includes the forming of the firstlayer of resin impregnated paper from melamine impregnated decor paper.In addition, the method may include the painting of an exposed face ofthe first layer of resin impregnated paper with a radiation cured paint.In yet another possible embodiment the method may include the paintingof an exposed face of the first layer of resin impregnated paper with athermally crosslinked urethane acrylate paint.

In the following description there is shown and described severaldifferent embodiments of this invention, simply by way of illustrationof some of the modes best suited to carry out the invention. As it willbe realized, the invention is capable of other different embodiments andits several details are capable of modification in various, obviousaspects all without departing from the invention. Accordingly, thedrawings and descriptions will be regarded as illustrative in nature andnot as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification, illustrate several aspects of the present invention, andtogether with the description serve to explain certain principles of theinvention. In the drawings:

FIG. 1 is a side elevational view of one possible embodiment of thepresent invention;

FIG. 2 is a side elevational view of a first alternative embodiment ofthe present invention;

FIG. 3 is a side elevational view of yet another possible embodiment ofthe present invention;

FIG. 4 a is a total heat release graph comparing two representativeexamples of the present invention with two representative state of theart products; and

FIG. 4 b is a heat release rate graph comparing the same tworepresentative examples of the present invention with two representativestate of the art products.

Reference will now be made in detail to the present preferred embodimentof the invention, an example of which is illustrated in the accompanyingdrawings.

Detailed Description and Preferred Embodiments of the Invention

Three possible embodiments of the high pressure laminate 10 of thepresent invention are illustrated in FIGS. 1-3. The high pressurelaminate 10 may be generally described as comprising a first layer ofresin impregnated paper and at least one layer of fiber reinforced veil,Each layer of fiber reinforced veil further includes a secondary binderand filler so that the high pressure laminate is characterized by havinga caloric value of lower than 3.0 MJ/kg when tested in accordance withISO 1716. The term “secondary binder” is defined as a binder which isapplied in a second processing step which is discussed in more detailbelow.

As illustrated in the FIG. 1 embodiment, the high pressure laminate 10includes a first layer 12 of resin impregnated paper, such as melamineimpregnated decor paper. In addition, the laminate 10 includes twolayers 14, 16 of fiber reinforced veil.

Each layer 14, 16 of fiber reinforced veil is impregnated with asecondary binder and filler composition. The secondary binder is a heatcurable resin. Typically, the secondary binder is selected from a groupconsisting of melamine-formaldehyde, phenol-formaldehyde,urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkableacrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamideresin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamideresin and mixtures thereof.

The filler is selected from a group consisting of metal hydroxides,metal carbonates, titanium dioxide, calcined clay, barium sulfate,magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite,diatomite, feldspar, mica, nepheline syenite, pyrophyllite (aluminumsilicate), silica, talc, wollastonite, montmorillonite (bentonite),hectorite, saponite, calcium carbonate, magnesium carbonate, aluminumoxide, iron oxide, magnesium hydroxide, glass micro beads and mixturesthereof. Typically the filler is selected from a group consisting ofmetal hydroxides, metal carbonates and mixtures thereof. A mixture ofcalcium carbonate and aluminum hydroxide is particularly useful in thepresent invention. This is particularly true when used in conjunctionwith a melamine-formaldehyde binder. The particle size of the fillerstypically ranges from about 0.3 μm to about 150 μm, more preferablybetween about 1 μm to about 75 μm, and most preferably between about 4μm to about 50 μm.

The fiber reinforced veil includes reinforcing fibers selected from agroup consisting of glass fibers, basalt fibers, inorganic fibers(carbide, nitride, etc.) and mixtures thereof. Glass fibers particularlyuseful in the present invention include E-glass (such as Advantexglass), ECR-glass, AR-glass, C-glass, M-glass, D-glass, S-glass,S2-glass and mixtures thereof. The fibers are typically chopped inlengths of between about 0.1 mm and 100 mm and may be in the forms ofchopped strands, chopped rovings or chopped individual fibers ormixtures thereof. Where individual fibers are utilized, the diameter ofthose fibers is typically between about 3 and about 50 microns.

The fiber reinforced veils, prior to impregnation of the secondarybinder and fillers, contain up to about 95 weight percent glass fibers,preferably between about 75 to about 95 weight percent glass fibers,more preferably between about 78 to about 93 weight percent glassfibers, and most preferably between about 80 to about 92.5 weightpercent glass fibers. Preferably, the fiber reinforced veil layerincludes E-glass fibers.

The fiber reinforced veil, prior to impregnation of the secondary bindercomposition and fillers, may include a binder, as mentioned above,preferably the binder is a polyvinyl alcohol. Preferably, the binder ispresent in the veil at a content of about 5 to about 25 percent byweight.

In the embodiment illustrated in FIG. 1, the laminate 10 incorporatestwo layers 14, 16 of veil. Each veil layer 14, 16 may be woven ornonwoven. In the embodiment illustrated in FIG. 1, both veil layers 14,16 may be woven, both may be nonwoven or one may be woven while theother is nonwoven.

A particularly useful embodiment of the present invention incorporatesone or more veil layers 14, 16 including between about 1 and about 95weight percent reinforcement fibers, preferably between about 75 weightpercent to about 95 weight percent reinforcement fibers, more preferablybetween about 78 to about 93 weight percent reinforcement fibers, mostpreferably between about 80 to about 92.5 weight percent reinforcementfibers, prior to impregnation of the secondary binder composition andfillers. The veil layers also contain between about 2 to about 50 weightpercent, preferably between about 5 to about 25 weight percentmelamine-formaldehyde secondary binder and at least one filler in theamount of between about 10 and about 80 weight percent, preferablybetween about 17.5 to about 65 weight percent calcium carbonate andabout 20 to about 90 weight percent, preferably about 35 to about 70weight percent aluminum hydroxide.

As further illustrated in FIG. 1, the laminate 10 may be made moreaesthetically pleasing by including a radiation curable paint such as anelectron beam cured or UV cured paint film 18 on an otherwise exposedface of the first layer of resin impregnated paper 12. Alternatively,the layer 18 may comprise a thermally cross-linked urethane acrylatepaint.

An alternative embodiment of the present invention is illustrated inFIG. 2. In this embodiment, the high pressure laminate 10 includes asingle fiber reinforced veil layer 20 sandwiched between first andsecond layers 22, 24 of resin impregnated paper. The laminate 10 of FIG.2 may also include a layer 26 of radiation cured paint such as anelectron beam cured or UV cured paint film or a thermally cross-linkedurethane acrylate paint. The layer 26 is, however, optional.

In still another embodiment illustrated in FIG. 3, the laminate 10 mayinclude a first layer 28 of resin impregnated paper, six intermediatelayers 30, 32, 34, 36, 38, 40 of fiber reinforced veil and a secondlayer 42 of resin impregnated paper. The FIG. 3 embodiment may alsoinclude an optional layer 44 comprising a radiation cured paint such asan electron beam or UV cured paint film or a thermally cross-linkedurethane acrylate paint layer for enhanced aesthetic appearance.

It should be appreciated that the resin impregnated paper layers 22, 24,28 and 42 of the embodiments illustrated in FIGS. 2 and 3 are similar oridentical to the resin impregnated paper layer 12 of the firstembodiment illustrated in FIG. 1. Similarly, the fiber reinforced veillayers 20, 30, 32, 34, 36, 38, 40 of the embodiments illustrated inFIGS. 2 and 3 are also identical or similar to the veil layers 14, 16 ofthe FIG. 1 embodiment. As illustrated, the laminate 10 of the presentinvention may include any number of fiber reinforced veil layers whilestill meeting the fire propagation, caloric value and mechanicalproperties of any particular end product application.

Typically, each fiber reinforced veil layer is a prepreg orready-to-mold sheet of woven or nonwoven reinforcement fibersimpregnated with a resin binder and stored for subsequent use such asthe final construction of the laminate product by a manufacturer. Anywater-based, wet strength binder known in the art could be used. Usefulbinders include but are not limited to the following polyvinyl alcohol,(partially hydrolyzed) polyvinyl acetate, acrylic polymers andcopolymers, crosslinkable acrylic polymers and copolymers, polymerizablepolyfunctional N-methylol compounds, notably N-methylol ureas such asdimethylol urea and N-methylol melamine type resins, melamineformaldehyde, phenol formaldehyde, furfuryl formaldehyde, resorcinolformaldehyde, styrene butadiene copolymer latices, cationicpolyamideepichlorohydrin, aminoresins, epoxyresins, polystyrene emulsionbinder, polycarboxylic acid based binders, other latices and/or acrylicpolymers or copolymers like acrylamide, ethylene vinyl acetate/vinylchloride, alkyl acrylate polymer,styrene-butadiene rubber, acrylonitrilepolymer, polyurethane resins, polyvinyl chloride, polyvinylidenechloride, copolymers of vinylidene chloride with other monomers,polyvinyl acetate, polyvinyl pyrrolidone, polyester resins, acrylateemulsion resin, styrene acrylate. More preferably, the binder ispolyvinyl alcohol.

The prepreg is impregnated with the secondary binder and fillercomposition. The secondary binder and filler composition preferablyincludes between about 2 to about 30 weight percent glass, in additionto the glass already present in the prepreg, more preferably betweenabout 3 to about 25 weight percent glass, and most preferably betweenabout 4 to about 20 weight percent glass. The prepreg also containsbetween about 5 to about 25 weight percent secondary binder, preferablybetween about 7 to about 20 weight percent secondary binder, mostpreferably between about 8 to about 18 weight percent secondary binder.The prepreg also contains between about 50 to about 93 weight percentfillers, more preferably between about 55 to about 90 weight percentfillers and most preferably between about 60 to about 88 weight percenttotal fillers.

Typically the filler is a mixture of metal hydroxide and metal carbonateat a ratio of between about 1:0.01 and about 1:100. Preferably, themetal hydroxide aluminum hydroxide and is present in the prepreg theamount of between about 20 to about 90 weight percent, more preferablybetween about 30 to about 80 weight percent, and most preferably betweenabout 35 to about 70 weight percent. The preferred metal carbonate iscalcium carbonate and is present in the prepreg in the amount of about10 to about 80 weight percent, more preferably about 15 to about 70weight percent and most preferably between about 17.5 to about 65 weightpercent.

The particle size of the fillers typically ranges from about 0.3 μm toabout 150 μm, more preferably between about 1 μm to about 75 μm, andmost preferably between about 4 μm to about 50 μm.

Following impregnation, and before pressing, a typical fiber reinforcedveil prepreg will have a total weight per unit area of between about 250g/m² and about 2000 g/m², a density of between about 500 kg/m³ and about2000 kg/m³ The high pressure laminate 10 is constructed by pressing afirst layer of resin impregnated paper and at least one layer of fiberreinforced veil together at a pressure of between about 525 N/m² andabout 15,750 N/m² (about 5 and about 150 bar) while simultaneouslyheating the layers to a temperature of between about 120 degrees C. andabout 220 degrees C. to form the laminate. In addition the methodincludes the step of using a combination of binder and filler to providea caloric value of lower than 3.0 MJ/kg when the laminate is tested inaccordance with ISO 1716. This allows one to produce an HPL panel orproduct with an SBI A2 classification.

In order to achieve this end, the secondary binder is selected from agroup consisting of melamine-formaldehyde, phenol-formaldehyde,urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkableacrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamideresin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamideresin and mixtures thereof. The filler is selected from a group ofmaterials consisting of metal hydroxides, metal carbonates, titaniumdioxide, calcined clay, barium sulfate, magnesium sulfate, aluminumsulfate, zinc oxide, kaolin clay, chlorite, diatomite, feldspar, mica,nepheline syenite, pyrophyllite (aluminum silicate), silica, talc,wollastonite, montmorillonite (bentonite), hectorite, saponite, calciumcarbonate, magnesium carbonate, aluminum oxide, iron oxide, magnesiumhydroxide, glass micro beads and mixtures thereof.

Typically, the filler is selected from a group consisting of metalhydroxides, metal carbonates and mixtures thereof. Calcium carbonate andaluminum hydroxide are particularly useful in this method.

In order to further enhance the aesthetic appeal of the product, themethod may also include forming the first layer of resin impregnatedpaper from melamine impregnated decor paper. Further, the method mayinclude painting an exposed face of the first layer of resin impregnatedpaper with electron beam cured paint. Alternatively the method mayinclude painting an exposed face of the first layer of resin impregnatedpaper with a thermally crosslinked urethane acrylate paint.

The following example is presented to further illustrate the invention,but it is not to be considered as limited thereto.

EXAMPLE

Five examples of a high pressure laminate of the present invention wereprepared. In the first (Example 1), five fiber reinforced glass veilswere sandwiched between two layers of melamine formaldehyde impregnateddecorative paper.

The glass fiber utilized in the glass veils was E-glass having a fiberdiameter of 11 microns and a length of 10 mm. The glass veils each had aweight per unit area of 100 g/m². The glass veils included a poly vinylalcohol binder at a content of 16 weight percent.

The decorative paper layers each had a weight per unit area of 160 g/m²including 80 g/m² base weight paper and 80 g/m² melamine formaldehyderesin.

The stacked layers of glass veil were then impregnated with a secondarybinder and filler formulation including 21 weight percent phenolformaldehyde, 26 weight percent calcium carbonate and 53 weight percentaluminum hydroxide. The final glass veil weight was 1000 g/m².

The stacked layers were pressed together at a pressure of 100 kg/cm² ata temperature of 150 degrees C. for 20 minutes to produce a 2.96 mmthick laminate.

In the second (Example 2), five fiber reinforced glass veils weresandwiched between a layer of melamine formaldehyde decorative paper anda layer of phenol formaldehyde impregnated kraft paper.

The glass fibers utilized in the Example 2 product were E-glass having afiber diameter of 13 microns and a length of 11 mm. The glass veils eachhad a weight per unit area of 50 g/m² and included a poly vinyl alcoholbinder at a content of 14 weight percent.

The stacked layers of glass veil were impregnated with a secondarybinder and filler formulation of 15 weight percent melamineformaldehyde, 20 weight percent calcium carbonate and 65 weight percentaluminum hydroxide. The final glass veil weight was 900 g/m².

The stacked layers of the Example 2 product were pressed together at apressure of 50 kg/cm² at a temperature of 145 degrees C. for 20 minutesin order to produce a 3 mm thick laminate.

Additional Examples 3, 4 and 5 of the present invention are presented inTable 1 below along with Examples 1 and 2. Additionally, the Tableincludes corresponding measurements for representative state of the artHPL (std HPL) and state of the art FR-HPL (fire retardant HPL) productsfor purposes of comparison. Test results for each of these Examples 1-5and the state of the art products std HPL and FR-HPL are presented(where available) in Table 2. Relevant total heat release (THR) and heatrelease rate (HRR) curves are illustrated respectively in FIGS. 4 a and4 b.

The foregoing description of the preferred embodiments of the inventionhave been presented for purposes of illustration and description. It isnot intended to be exhaustive or to limit the invention to the preciseform disclosed. Obvious modifications or variations are possible inlight of the above teachings.

The embodiments were chosen and described to provide the bestillustration of the principles of the invention and its practicalapplication to thereby enable one of ordinary skill in the art toutilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplated. All suchmodifications and variations are within the scope of the invention asdetermined by the appended claims when interpreted in accordance withthe breadth to which they are fairly, legally and equitably entitled.The drawings and preferred embodiment do not and are not intended tolimit the ordinary meaning of the claims and their fair and broadinterpretation in any way.

1. A high pressure laminate, comprising: a first layer of resinimpregnated paper; and at least one layer of fiber reinforced veil, eachlayer of fiber reinforced veil being impregnated with a secondary binderand at least one filler; said high pressure laminate being characterizedby having a caloric value of lower than about 3.0 MJ/kg when tested inaccordance with ISO
 1716. 2. The laminate of claim 1 including a secondlayer of resin impregnated paper, said at least one layer of fiberreinforced veil being sandwiched between said first and second layers ofresin impregnated paper.
 3. The laminate of claim 1, wherein saidsecondary binder is a heat curable resin.
 4. The laminate of claim 3wherein said secondary binder is selected from a group consisting ofmelamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxyresin, unsaturated polyesters, cross-linkable acrylic resin,polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, anepichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin andmixtures thereof.
 5. The laminate of claim 3, wherein said filler isselected from a group consisting of metal hydroxides, metal carbonates,titanium dioxide, calcined clay, barium sulfate, magnesium sulfate,aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite,feldspar, mica, nepheline syenite, pyrophyllite, silica, talc,wollastonite, montmorillonite, hectorite, saponite, calcium carbonate,magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide,glass micro beads and mixtures thereof.
 6. The laminate of claim 1,wherein said filler is selected from a group consisting of metalhydroxides, metal carbonates and mixtures thereof.
 7. The laminate ofclaim 6, wherein said mixtures of metal hydroxides to metal carbonatesare provided at a ratio of between about 1:0.01 and about 1:100.
 8. Thelaminate of claim 1, wherein said filler is selected from a mixture ofcalcium carbonate and aluminum hydroxide.
 9. The laminate of claim 8wherein said secondary binder is melamine-formaldehyde.
 10. The laminateof claim 9, wherein each said layer of fiber reinforced veil followingimpregnation includes between about 1 and about 95 weight percentreinforcement fibers, about 2 and about 50 weight percentmelamine-formaldehyde, between about 1 and about 85 weight percentcalcium carbonate and about 1 and about 85 weight percent aluminumhydroxide.
 11. The laminate of claim 10 wherein each said layer of fiberreinforced veil following impregnation and prior to pressing has aweight per unit area of between about 250 g/m² and about 2000 g/m² and adensity of between about 500 kg/m³ and about 2000 kg/m³.
 12. Thelaminate of claim 10, wherein said reinforcement fibers are glass fibersselected from a group consisting of E-glass, ECR-glass, AR-glass,M-glass, D-glass, C-glass, S-glass, S2-glass and mixtures thereof. 13.The laminate of claim 1 wherein said at least one layer of fiberreinforced veil is woven.
 14. The laminate of claim 1, wherein said atleast one layer of fiber reinforced veil is nonwoven.
 15. The laminateof claim 1, including at least two layers of fiber reinforced veilwherein a first layer of said two layers is woven and a second layer ofsaid two layers is nonwoven.
 16. The laminate of claim 1, wherein saidat least one fiber reinforced veil includes reinforcing fibers selectedfrom a group consisting of glass fibers, basalt fibers, inorganic fibersand mixtures thereof.
 17. The laminate of claim 1, wherein said at leastone fiber reinforced veil includes chopped glass fibers
 18. The laminateof claim 17, wherein said chopped glass fibers include chopped glassstrands, chopped glass rovings, individual chopped glass fibers andmixtures thereof.
 19. The laminate of claim 1, wherein said first layerof resin impregnated paper is a melamine impregnated decor paper. 20.The laminate of claim 1, further including a radiation cured paint filmon an exposed face of said first layer of resin impregnated paper. 21.The laminate of claim 1, further including a thermally cross-linkedurethane acrylate paint layer on an exposed face of said first layer ofresin impregnated paper.
 22. A fiber reinforced veil comprising asecondary binder and at least one filler; wherein said veil has acaloric value of lower than about 3.0 MJ/kg when tested in accordancewith ISO
 1716. 23. The fiber reinforced veil of claim 22, wherein saidsecondary binder is selected from the group consisting ofmelamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxyresin, unsaturated polyesters, cross-linkable acrylic resin,polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, anepichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin andmixtures thereof.
 24. The fiber reinforced veil of claim 22, furthercomprising a binder selected from the group consisting of polyvinylalcohol, (partially hydrolyzed) polyvinyl acetate, acrylic polymers andcopolymers, crosslinkable acrylic polymers and copolymers, polymerizablepolyfunctional N-methylol compounds, notably N-methylol ureas such asdimethylol urea and N-methylol melamine type resins, melamineformaldehyde, phenol formaldehyde, furfuryl formaldehyde, resorcinolformaldehyde, styrene butadiene copolymer latices, cationicpolyamideepichlorohydrin, aminoresins, epoxyresins, polystyrene emulsionbinder, polycarboxylic acid based binders, other latices and/or acrylicpolymers or copolymers like acrylamide, ethylene vinyl acetate/vinylchloride, alkyl acrylate polymer,styrene-butadiene rubber, acrylonitrilepolymer, polyurethane resins, polyvinyl chloride, polyvinylidenechloride, copolymers of vinylidene chloride with other monomers,polyvinyl acetate, polyvinyl pyrrolidone, polyester resins, acrylateemulsion resin, and styrene acrylate.
 25. The fiber reinforced veil ofclaim 22, wherein said filler is selected from a group consisting ofmetal hydroxides, metal carbonates, titanium dioxide, calcined clay,barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolinclay, chlorite, diatomite, feldspar, mica, nepheline syenite,pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite,saponite, calcium carbonate, magnesium carbonate, aluminum oxide, ironoxide, magnesium hydroxide, glass micro beads and mixtures thereof. 26.The fiber reinforced veil of claim 22, wherein said fiber reinforcedveil includes reinforcing fibers selected from a group consisting ofglass fibers, basalt fibers, inorganic fibers and mixtures thereof. 27.A method of making a high pressure laminate, comprising: pressing afirst layer of resin impregnated paper and at least one layer of fiberreinforced veil together at a pressure and temperature sufficient tolaminate said paper and said at least one layer of veil together; andimpregnating said paper and said fiber reinforcing veil with a secondarybinder and at least one filler to provide a caloric value of lower than3.0 MJ/kg when said laminate is tested in accordance with ISO
 1716. 28.The method of claim 27 wherein said step of pressing said paper and saidveil together further includes pressing said paper and said veiltogether at a pressure of between about 525 N/N/m² and about 15,750 N/m²and simultaneously heating said paper and said veil at a temperature ofbetween about 120 degrees C. and about 220 degrees C.
 29. The method ofclaim 27 including selecting said secondary binder from a groupconsisting of melamine-formaldehyde, phenol-formaldehyde,urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkableacrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamideresin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamideresin and mixtures thereof.
 30. The method of claim 29, includingselecting said filler from a group consisting of metal hydroxides, metalcarbonates, titanium dioxide, calcined clay, barium sulfate, magnesiumsulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite,feldspar, mica, nepheline syenite, pyrophyllite, silica, talc,wollastonite, montmorillonite, hectorite, saponite, calcium carbonate,magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide,glass micro beads and mixtures thereof.
 31. The method of claim 29,including selecting said filler from a group consisting of metalhydroxides, metal carbonates and mixtures thereof.
 32. The method ofclaim 29, including selecting said filler from a mixture of calciumcarbonate and aluminum hydroxide.
 33. The method of claim 27, includingselecting said filler from a group consisting of metal hydroxides, metalcarbonates and mixtures thereof.
 34. The method of claim 27, includingselecting said filler from a mixture of calcium carbonate and aluminumhydroxide.
 35. The method of claim 27, further including forming saidfirst layer of resin impregnated paper from melamine impregnated decorpaper.
 36. The method of claim 27, further including painting an exposedface of said first layer of resin impregnated paper with radiation curedpaint.
 37. The method of claim 27 further including painting an exposedface of said first layer of resin impregnated paper with a thermallycrosslinked urethane acrylate paint.